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Hybrid Technical Overview. 2 This is a big deal! $1.45 + fuel & over $128 per barrel of oil US Supreme Court decision on green house gases –EPA must now.

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Presentation on theme: "Hybrid Technical Overview. 2 This is a big deal! $1.45 + fuel & over $128 per barrel of oil US Supreme Court decision on green house gases –EPA must now."— Presentation transcript:

1 Hybrid Technical Overview

2 2 This is a big deal! $ fuel & over $128 per barrel of oil US Supreme Court decision on green house gases –EPA must now regulate CO2 –21 States already with emissions or Green House Gas Legislation Platforms of the Future –Must Save Fuel –PLUS: 2010 Emissions Technology

3 3 Note: 2007 diesel emissions really does not impact green house gases or CO2. The reduction is in NOx and PM. The only way to reduce CO2 emissions in any magnitude is to not to burn the fuel. Note: 2007 diesel emissions really does not impact green house gases or CO2. The reduction is in NOx and PM. The only way to reduce CO2 emissions in any magnitude is to not to burn the fuel / NOx (g/hp-hr) PM (g/hp-hr) ULSD 15 PPM (6/06) 500 PPM (6/93) SULFURContent In Fuel 1994 ASH/SulfurContent In Oil Ash1.5% Ash1.0% Sulfur.8% Sulfur.4% Emissions Reductions

4 4 Why Hybrid Trucks? Impacts on the future of diesel transportation –Environmental issues –Energy issues Fuel efficiency Climate change Clean air

5 5 What Makes The System Work? Eaton Hybrid Electric Power Train - Hybrid drive system components International® Diamond Logic ® Electrical System - Complete electronic vehicle integration - Optimization body of functions

6 6 Fully Integrated Chassis & Body

7 7 Controls minimize operational differences for the operator Non- Hybrid Standard Controls Hybrid Standard Controls Standard Controls

8 8 Full J-1939 Communications - entire vehicle Full diagnostics & system communication Optimization of e-PTO system w/engine off Fuel economy – system time-outs Chassis body equipment interlocks – Protect equipment – Protect operators Body equipment customization Hybrid Chassis and Body Integration Diamond Logic® is the key to body / chassis integration.

9 9 Customers Companies with “green” corporate culture  Food service, beverage, pickup & delivery Customers impacted by legislation  All Governments, non-attainment cities, Utilities Early “leading edge” technology adaptors  Change agents (electrification of the reefer)

10 Utility Truck Emissions Reduced** Over the road & Worksite Ops ** Based on independent 3 rd party testing Over the Road Engine off work-site Dollars & Gallons of Fuel Saved Annually Hybrid Car* P&D kms 6 hrs / day Work-site Ops ~ 3800 – 5700 lt Saved 11 – 16.5 Tons of CO2 Reduced $690 * lt 20,000 kms Utility ~ $2,500 to $3,800 * 2 * 1 Assume $3.52 gal; 21mpg; 30% improvement * 2 $1.45 fuel * 3 Assume baseline: 7.5 mpg & 1.18 gph idle ~ 2300 – 3400 lt Saved 6.6 – 9.9 Tons of CO2 Reduced 32,000 kms 20,000 kms 3 hrs / day Work-site Ops ~ $5500 to $8300 * 2,3 ~ 4550 – 7200 lt Saved 13.2 – 21 Tons of CO2 Reduced ~ $6,600 to $10,500 * 2,3 Fuel Saved – Emissions Reduced On 2006 Emissions Engines P&D – 30-50% fuel economy improvement Utility – 40-60% fuel consumption reduction

11 11 Fuel Economy Improvements Keys to improvements –Intercity application critical (Duty Cycle) –Regenerative braking –Idle reduction Expectations –30 to 60% fuel economy improvement –Reduced emissions –Reduced maintenance –Bio-diesel approved (B-20) The only way you can reduce greenhouse gases is to not burn the fuel!

12 12 Application Coverage 23,500 to 33,000 GVW Base System Van applications Beverage Armored car Pickup & delivery Stake flat Shuttle bus e-PTO System Utility (A erial / Service) Tree aerial bucket Crane Recovery vehicle

13 13 MaxxForce DT 225HP (560 & 620 lbs/ft ratings) Exhaust after treatment options: RH horz/horz RH under cab horz RH horz./vertical tailpipe Factory-released e-PTO software for optimized engine-off PTO use Cruise control availability New vanity cover for PEC Vehicle feature requirements Air brakes 22.5” Wheels On/off fan drive Up to 33,000 GCWR 2008 HEV DuraStar Spec Update

14 14 DC/DC Converter Power Electronics Carrier (Battery Box) Motor Inverter/Controller Hybrid Drive Unit (HDU) Primary Hybrid Components Maximize payload weight and space ~ 450 lbs. additional weight over a non-hybrid equipped chassis

15 15 Hybrid System Component Location Hybrid Drive Unit PEC (Hybrid Batteries) Controller/Inverter & DC/DC Converter 12V Batteries Hybrid System Heat Exchanger Hybrid Cooling Reservoir

16 16

17 17 20” 52” 13” Temporary Mount Power Electronics Carrier (PEC) Hybrid High Voltage Batteries

18 18 Power Electronics Carrier (PEC) Hybrid High Voltage Batteries Chassis (12 volt Batteries)

19 19 Traditional Drivetrain ENGINE HP T kW + Motor/Generator T engine hp kW + Hybrid Drivetrain Same Vehicle Torque Output Mild Parallel Hybrid System Pre-Transmission

20 Acceleration 9 seconds faster to 60 mph at full throttle

21 21 System Description and Operating Modes

22 Fuller Automated Transmission (AMT) Hybrid Electric Motor Electric Clutch 120AC/60Hz Power Panel Auxiliary Power Generator (AGP) Inverter Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls Motor Controller/Inverter DC/DC Converter Hybrid System Diagram

23 Fuller Automated Transmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls Motor Controller/Inverter Direct Hybrid – Engine Starting Mode Engine

24 Fuller Automated Transmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls Motor Controller/Inverter Direct Hybrid – Electric Only Mode Engine (Idle) Drive Torque Discharge Mode

25 Fuller Automated Transmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls Motor Controller/Inverter Direct Hybrid – Engine & Motor Drive Mode Engine Torque Discharge Mode

26 Fuller Automated Transmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls Motor Controller/Inverter Direct Hybrid – Engine Only Mode Engine Torque Charging Mode Optional

27 Fuller Automated Transmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls Motor Controller/Inverter Direct Hybrid – Braking/Regeneration Mode Engine Torque Charging Mode; Regen Braking

28 28 Drives AC loads from hybrid battery source V DC to 120V AC at 5 KW (6KW peak) 3 x individually GFCI-protected duplex outlets Two-part design enables flexible mounting IP67 for chassis mounting Liquid cooled Auxiliary Power Generation (APG) Update

29 Fuller Automated Transmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls Motor Controller/Inverter Direct Hybrid – Engine off e-PTO & APG Engine Discharge Mode Auxiliary Power Generator (APG)

30 Fuller Automated Transmission (AMT) Hybrid Electric Motor Auto Clutch Engaged Power Electronics Carrier (PEC) Lithium Ion Batteries Battery Controls Motor Controller/Inverter Direct Hybrid – Engine on e-PTO & APG Engine (Idle) Auxiliary Power Generator (APG) Charge Mode

31 31 Diamond Logic® Builder Equipment up-fitters must be minimum DLB Level 2 certified to further improve HEV efficiency for any hybrid parameter or software modification using International’s DLB. e-PTO System m-PTO System

32 32 Hybrid Launch Completed test validation –Beverage Van unit in service for more than 2 years 37% improvement in fuel economy with 97% uptime –24 HTUF units running for better than 3 years –27 additional units built with 2006 engines Positive results to date million milesPositive results to date million miles –49 units built with 2007 engines –Additional orders in-house

33 33 Eaton Hybrid Warranty Standard warranty - 3 years / 240,000 kms –Includes base transmission and Eaton-supplied hybrid system* * Cooling portion of system International Truck & Engine-supplied 5 year extended warranty coverage - coming

34 34 Hybrid Life Cycle Costs PEC requires air filter changes every 4-6 months - $15.00 (retail) X 10 = $ Transmission oil (E500 synthetic lube) - No change required for 800,000 kms* Grease Zerk through inspection cover for upper clutch cross shaft roller bearing *Rugged applications require oil change at 2,000 hours or 5 years. 5 Year Projected Maintenance

35 35 Battery Life Expectancy Current life projection 6-8 years Strongly dependant upon application, duty cycle –Continued focus on PEC serviceability Component exchange program Reman program

36 36 Dependent on –Price of fuel –Green house gas legislation –Body application Average $5.50/gal. diesel over next 8 years –Base 8 Years = $26,400 to $24,750 –e-PTO System 8 Years = $44,000 – $66,000 –e-PTO System 8 Years = $52,800 - $83,600 It’s the right thing to do! Business Case For Hybrid

37 37 1. Reduces fuel consumption 2. Reduces emissions and green house gases 3. Assembly line production of HEV System 4. Over 2 years of in-service testing of system across North America 5. Complete HEV vehicle system warranty from one source 6. Improved corporate “green” social image 7. Assistance to body builders to integrate and advantage hybrid system 8. Enhance vehicle performance and productivity 9. Fully integrated engine, transmission and vehicle electronics 10. International dealer service network support Top Ten Reasons To Choose

38 38 How Do You Identify A Hybrid? Vehicle displays “Hybrid” on the outside Dashboard shift label displays “Eaton Hybrid” Presence of bright orange high voltage cables Watch for the new TSI Hybrid

39 39 How Do You Identify A Hybrid?

40 40 How Do You Identify A Hybrid? Shift Label on “doghouse” inside cab

41 41 How Do You Identify A Hybrid? Orange High Voltage Cables

42 42 High Voltage Components Motor/Generator Always located between engine flywheel and transmission

43 43 High Voltage Components Inverter located on left side on frame rail

44 44 High Voltage Components Power Electronics Carrier - Standard location on left side on frame rail Can be mounted on body equipment

45 45 High Voltage Components DC/DC Converter (e-PTO) - Located on left side on frame rail

46 46 Emergency Procedure Preferred Option – Turn off ignition key –High-voltage batteries still alive but isolated in PEC Option 2 – Disconnect low voltage 12V batteries –High-voltage batteries still alive but isolated in PEC Option 3 – Push in “Service Switch” on PEC –Shuts down engine –High-voltage batteries still alive but isolated in PEC Shutdown After the vehicle is disabled, power is maintained up to 5 minutes in the high-voltage electrical system.

47 47 Do’s Always assume vehicle is “live.” Always perform one of three Emergency Shutdown Procedures. Before working on the vehicle, allow vehicle to sit for 5 minutes.

48 48 Don’ts Never work on the vehicle if Emergency Shutdown Procedures are not complete. Never work on vehicle if the vehicle hasn’t set for five minutes. Never cut orange high-voltage cables. Never cut into or open –Inverter –PEC –DC/DC Converter

49 49 Vehicle towing and jumpstarting

50 Thank You!


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